Monitoring the pressure profile in the cavity without installing a sensor there: The patent-pending intelliGate-p technology from Männer, a SPECTRIX brand, integrates the measurement point into the valve pin holder of the hot runner system. Comparative measurements with conventional cavity pressure sensors confirm comparable measurement accuracy. The system also detects tensile forces acting on the valve pin during opening and demolding. Following successful technical testing, SPECTRIX is now seeking partners for long-term use under industrial conditions.
Whether for real-time process monitoring, automatic identification of good parts or, potentially, predictive maintenance, the cavity pressure profile provides plastics processors with valuable information about the stability and quality of the injection molding process.
However, mold makers are often reluctant to install sensors and the necessary wiring. Installing conventional cavity pressure sensors involves additional work. Required installation space, additional machining, wiring, and continued sensor accessibility and functionality must all be considered. Direct contact with the melt can also leave sensor witness marks on the molded part, while high thermal loads can affect sensor service life.
Measurement Directly at the Gate Position
In intelliGate-p, a piezoelectric sensor is located in the valve pin holder of the hot runner system. It measures the force exerted on the valve pin by the melt pressure, providing a reliable representation of the cavity pressure profile. The cavity surface remains unchanged, and no additional sensor bore is required in the cavity. Existing molds can also be retrofitted with only minor modifications.
The system combines Männer’s hot runner expertise with Priamus’s expertise in sensor technology and process monitoring. The development team led by Christian Estorer and Johannes Bamberger brings these capabilities together within SPECTRIX. Mold makers receive hot runner and sensor technology from a single source.
intelliGate-p is designed primarily for small to medium-sized parts produced in high volumes with short cycle times. Typical applications include multicavity molds for packaging and disposable medical products – areas in which Männer has extensive experience.
Tensile Forces Provide Additional Process Information
Christian Estorer, Manager Hot Runner Development R&D, sees a key advantage in the fixed measurement position: The sensor sits directly behind the valve pin at the gate position. Its installation location therefore does not need to be determined individually for each mold. Comparative measurements with conventional cavity pressure sensors confirm comparable measurement accuracy.
In addition, intelliGate-p detects a negative peak when the valve pin opens, caused by tensile forces acting on the pin. These additional signals can help identify changes in the process and system condition at an early stage. Alongside the pressure profile, the system therefore provides information that conventional cavity pressure sensors do not capture in this form.
Easy Retrofitting of Existing Systems
Retrofitting intelliGate-p is particularly straightforward in Männer Signature Line valve gate systems equipped with the PS 48.2 pneumatic actuator. The piston, piston cover, valve pin and insulation plate are replaced. The sensor, connection cable and signal pickup are then added.
Customers have several options for processing the recorded measurement data. Those using process monitoring products such as Priamus Fillcontrol – also part of the SPECTRIX portfolio – can route the signals directly to the corresponding amplifier or first connect a Multi Channel Box, which combines signals from up to eight sensors.
intelliGate-p can also be connected to other suitable analysis and process monitoring systems, allowing flexible integration into existing production environments.
Reliably Revealing Relevant Process Changes
At high production volumes and short cycle times, even small process deviations can quickly result in large numbers of parts that do not meet specifications. intelliGate-p makes relevant changes visible and enables early intervention. The sensor is protected within the valve pin holder. The cavity surface remains unchanged, and no additional sensor wiring is required in the cavity-forming area. intelliGate-p thus combines precise process signals with a robust system architecture that is easy to integrate.
Johannes Bamberger, Team Lead Standardization, emphasizes: “The key advantage of intelliGate-p lies in the intelligent use of existing system components. Whereas conventional cavity pressure sensors must be installed directly in the cavity, modifying the cavity-forming area, intelliGate-p uses the existing valve pin as the interface for process monitoring. This allows us to rely on an established maintenance procedure, simplifying retrofitting and reducing service requirements. It makes the solution particularly robust, easy to service and durable.”
Partners Sought for Long-Term Use
intelliGate-p has successfully undergone extensive analyses and comparative measurements. Initial trials in customer-related applications have also shown positive results. SPECTRIX is now seeking application partners for long-term use under industrial conditions, in new projects or suitable existing molds. At Fakuma, interested visitors can explore the system on a demonstrator and discuss potential applications with the development team.
Männer and Priamus are part of SPECTRIX, a provider of end-to-end injection molding solutions.
The new intelliGate-p solution will be on display at Fakuma 2026 at the SPECTRIX booth in Hall A1, Booth 1208.
Figures:
Fig 1+2: Easy Retrofitting of a Männer PS 48.2 Pneumatic Actuator with the intelliGate-p Solution
About SPECTRIX
SPECTRIX brings together the industry-leading brands Männer, Foboha, Synventive, Thermoplay, Gammaflux, and Priamus. Combining more than 50 years of expertise with 2,000 specialists worldwide, SPECTRIX delivers the full spectrum of end-to-end injection molding solutions.
From part design and material science to molds, hot runners, sensing and control technologies, qualification, specialty molding, and lifecycle services, SPECTRIX supports every stage of the injection molding process. Customers can choose individual technologies and services or benefit from a fully integrated end-to-end solution tailored to their specific needs. With a global footprint and strong local expertise, SPECTRIX partners with customers from concept through series production.
SPECTRIX – Enduring Advantage, Engineered.
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